Spindle module, bank, and method

ABSTRACT

A pick-and-place spindle module comprises: a modular body structure including a first receiving location configured to receive a spindle; a first z-axis motor configured to move a spindle received in the first receiving location in a z-axis; a first theta motor configured to rotate a spindle received in the receiving location; a first motion control chip each attached to the body structure, the first motion control chip configured to control the first z-axis motor and the first theta motor; and a mechanical attachment mechanism, the mechanical attachment mechanism configured to facilitate attachment of the modular body structure to a spindle bank.

RELATED APPLICATIONS

This application claims priority to U.S. patent application Ser. No.16/969,751, filed Aug. 13, 2020, entitled “Dispensing Head, Nozzle andMethod,” which claims priority to International Patent Application No.PCT/US2018/019753, filed Feb. 26, 2018, entitled “Dispensing Head,Nozzle and Method,” the disclosures of which are hereby incorporated byreference to the extent that is it not inconsistent with the presentdisclosure.

BACKGROUND

Assembly machines include complex robots that have dispensing heads thatmove along one or more axis to assemble an unfinished product.Dispensing heads may be capable of picking, placing, providing materialto a component or surface, manipulating, screwing, or otherwisedispensing of a task or material. In pick-and-place assembly machines,for example, dispensing heads are often configured to receive multipledifferent spindle and nozzle assemblies in order to pick, place, andassemble various different parts efficiently. Dispensing heads mustoften include a spindle assembly for creating rotation in a nozzle,along with the ability to move the nozzle in the Z-axis. As a result ofthese requirements, dispensing heads for pick-and-place machines areoften heavy and have a large volume.

Further, assembly machines may include multi-spindle or multi-nozzledispensing heads. These dispensing heads may be configured to, forexample, pick up multiple components from one or more feeder banks, andthen move to a placement location to place the multiple components. Thisreduces assembly time compared to having a single spindle or singlenozzle. This is because single spindle and nozzle arrangements willtypically require the back and forth movement between the feeder banksand the placement location with each placed component. However, withadditional spindles and nozzle receivers located on a dispensing head,the size, volume and engineering complexity of the head is oftenincreased. Further, if one spindle or nozzle breaks or beginsfunctioning improperly, the entire dispensing head may be compromiseduntil such a problem is fixed.

Moreover, present dispensing heads for pick-and-place systems aretypically controlled by machine level processors or control systems.These systems preclude the creation of an independent motion controlprofile for each individual spindle on a multi-spindle dispensing head.Rather, motion control profiles are created on a dispensing head level.

Thus, improved assembly machines, dispensing heads, spindles, spindlemounting modules and spindle banks to alleviate or reduce one or more ofthe above limitations would be well received in the art.

BRIEF DESCRIPTION

According to one embodiment, a spindle for a pick-and-place machinecomprises: a shaft including a length extending between a first end anda second end, the shaft including an outer body and a hollow interior; anozzle tip disposed at the first end of the shaft, the nozzle tipconfigured to contact an electronic component for manipulation of theelectronic component; and a theta gear disposed on the shaft, the thetagear configured to engage with a motor of a pick-and-place head, whereinthe spindle is configured to be removably attachable from thepick-and-place head.

According to another embodiment, a method of assembly comprises:providing a pick-and-place machine having a pick-and-place head;providing a spindle for the pick-and-place machine, the spindleincluding: a shaft including a length extending between a first end anda second end, the shaft including an outer body and a hollow interior; anozzle tip disposed at the first end of the shaft; a theta gear disposedon the shaft; attaching the spindle to the pick-and-place head of thepick-and-place machine; engaging, by the theta gear, with a motor of thepick-and-place head; contacting, by the spindle, an electricalcomponent; manipulating, by the spindle, the electrical component; andremoving the spindle from the pick-and-place head of the pick-and-placemachine.

According to another embodiment, a dispensing head comprises: a bodystructure including a receiving location; a z-axis motor; a theta motor;a spindle received in the receiving location, the spindle comprising: ashaft including a length extending between a first end and a second end,the shaft including an outer body and a hollow interior; a nozzle tipdisposed at the first end of the shaft, the nozzle tip configured tocontact an electronic component for manipulation of the electroniccomponent; and a theta gear disposed on the shaft, the theta gearconfigured to engage with the theta motor such that the theta motor isconfigured to rotate the theta gear.

According to another embodiment, a spindle bank for a pick-and-placemachine comprises: a base including a plurality of mount locations, eachof the plurality of mount locations configured to receive a mountablespindle module including at least one pick-and-place spindle and nozzle;and a bearing system attachable to a movement axis of a pick-and-placemachine such that the spindle bank is movable along the movement axis.

According to another embodiment, a pick-and-place machine comprises: afeeder location configured to present electronic components for picking;a placement location configured to receive an unfinished product toplace the electronic components; a first movement axis; and a spindlebank including: a base including a plurality of mount locations, each ofthe plurality of mount locations configured to receive a mountablespindle module including at least one pick-and-place spindle and nozzle;and a bearing system attachable to the first movement axis such that thespindle bank is movable along the first movement axis.

According to another embodiment, a method of assembly comprising:providing a pick-and-place machine having a first movement axis;providing a spindle bank for a pick-and-place machine including: a baseincluding a plurality of mount locations; and a bearing systemattachable to the first movement axis of a pick-and-place machine suchthat the spindle bank is movable along the axis; and mounting, on eachof the plurality of mount locations, a mountable spindle moduleincluding at least one pick-and-place spindle and nozzle; andassembling, by the received mountable spindle modules, at least oneunfinished product.

According to another embodiment, a pick-and-place spindle modulecomprises: a modular body structure including a first receiving locationconfigured to receive a spindle; a first z-axis motor configured to movea spindle received in the first receiving location in a z-axis; a firsttheta motor configured to rotate a spindle received in the receivinglocation; an air distribution system including an air distribution port,the air distribution system configured to deliver received air from theair distribution port to a spindle received in the first receivinglocation; an electrical distribution system including an electricaldistribution port, the electrical distribution system configured todeliver received electricity from the electricity distribution port tothe first z-axis motor and the first theta motor; and a mechanicalattachment mechanism, the mechanical attachment mechanism configured tofacilitate attachment of the modular body structure to a spindle banksuch that the air distribution port is connected to receive air from thespindle bank and the electrical distribution port is configured toreceive electricity from the spindle bank.

According to another embodiment, a method of assembly comprises:providing a pick-and-place machine having a first movement axis;providing a spindle bank attached to the pick and place machine suchthat the spindle bank is movable along the first movement axis:providing a first pick-and-place spindle module including: a modularbody structure including a first receiving location; a first z-axismotor; a first theta motor; an air distribution system including an airdistribution port; an electrical distribution system including anelectrical distribution port; and a mechanical attachment mechanism;attaching, using the mechanical attachment mechanism, the firstpick-and-place spindle module to the spindle bank such that the airdistribution port is connected to receive air from an element of thespindle bank and the electrical distribution port is connected toreceive electricity from an element of the spindle bank; receiving, bythe receiving location of the modular body structure, a first spindle;moving, by the first z-axis motor, the received first spindle in az-axis; rotating, by the first theta motor, the received first spindle;delivering, by the air distribution system, received air from the airdistribution port to the received first spindle; delivering, by theelectrical distribution system, received electricity from the electricaldistribution port to the received first spindle; moving the spindle bankalong the first movement axis; and at least partially assembling, by theattached first pick-and-place spindle module, at least one unfinishedproduct.

According to another embodiment, a pick-and-place machine comprises: afeeder location configured to present electronic components for picking;a placement location configured to receive an unfinished product toplace the electronic components; a first movement axis; a spindle bankmovable along the first movement axis; and a pick-and-place spindlemodule attached to the spindle bank including: a modular body structureincluding a first receiving location configured to receive a spindle; afirst z-axis motor configured to move a spindle received in the firstreceiving location in a z-axis; a first theta motor configured to rotatea spindle received in the receiving location; an air distribution systemincluding an air distribution port, the air distribution systemconfigured to deliver received air from the air distribution port to aspindle received in the first receiving location; an electricaldistribution system including an electrical distribution port, theelectrical distribution system configured to deliver receivedelectricity from the electricity distribution port to the first z-axismotor and the first theta motor; and a mechanical attachment mechanism,the mechanical attachment mechanism attaching the modular body structureto the spindle bank such that the air distribution port is connected toreceive air and the electrical distribution port is configured toreceive electricity.

According to another embodiment, a pick-and-place spindle modulecomprises: a modular body structure including a first receiving locationconfigured to receive a spindle; a first z-axis motor configured to movea spindle received in the first receiving location in a z-axis; a firsttheta motor configured to rotate a spindle received in the receivinglocation; a first motion control chip each attached to the bodystructure, the first motion control chip configured to control the firstz-axis motor and the first theta motor; and a mechanical attachmentmechanism, the mechanical attachment mechanism configured to facilitateattachment of the modular body structure to a spindle bank.

According to another embodiment, a pick-and-place spindle bankcomprises: a base including a plurality of mount locations; a bearingsystem attachable to an axis of a pick-and-place machine such that thespindle bank is movable along the axis; and a first pick-and-placespindle module mounted to a first of the plurality of mount locations,the first pick-and-place spindle module including: a modular bodystructure including a first receiving location configured to receive aspindle; a first z-axis motor configured to move a spindle received inthe first receiving location in a z-axis; a first theta motor configuredto rotate a spindle received in the first receiving location; a firstmotion control chip each attached to the modular body structure, thefirst motion control chip configured to control the first z-axis motorand the first theta motor; and a mechanical attachment mechanismattaching the modular body structure to the base.

According to another embodiment, a pick-and-place head comprises: a bodystructure; a plurality of z-axis motors attached to the body structure,each configured to move a spindle in a z-axis; a plurality of thetamotors attached to the body structure each configured to rotate aspindle; and a plurality of motion control chips each attached to thebody structure, each of the plurality of motion control chips configuredto control a single one of the plurality of z-axis motors and a singleone of the plurality of theta motors.

According to another embodiment, a method of assembly comprises:providing a pick-and-place head that includes: a body structure; aplurality of z-axis motors attached to the body structure, eachconfigured to move a spindle in a z-axis; a plurality of theta motorsattached to the body structure each configured to rotate a spindle; anda plurality of motion control chips each attached to the body structure,controlling, with each of the plurality of motion control chips, asingle one of the plurality of z-axis motors and a single one of theplurality of theta motors; and at least partially assembling, with thepick and place head, an unfinished product.

According to another embodiment, a pick-and-place dispensing headcomprises: a body structure including a first z-axis motor attachmentlocation, a second z-axis motor attachment location, a first lineartrack and a second linear track; a first z-axis motor attached to thebody structure at the first z-axis motor attachment location; a secondz-axis motor attached to the body structure at the second z-axis motorattachment location; a first body attached to the first linear track andoperably connected to the first z-axis motor such that the first bodymoves along the first linear track when the first z-axis motor isactuated; a second body attached to the second linear track and operablyconnected to the second z-axis motor such that the second body movesalong the second linear track when the second z-axis motor is actuated;a first theta motor operably connected to the first body; a second thetamotor operably connected to the second body; a first receiving locationoperably connected to the first body, the first receiving locationconfigured to receive a pick-and-place spindle, wherein the first thetamotor is configured to rotate a pick-and-place spindle received in thefirst receiving location; and a second receiving location operablyconnected to the second body, the second receiving location configuredto receive a pick-and-place spindle, wherein the second theta motor isconfigured to rotate a pick-and-place spindle received in the secondreceiving location, wherein the first linear track and the second lineartrack are attached to the body structure with a set screw extendingbetween a first nut and a second nut.

According to another embodiment, a pick-and-place dispensing headcomprises: a body structure extending in an x-axis, a y-axisperpendicular to the x-axis, and a z-axis perpendicular to the x-axisand the y-axis, the body structure including a first z-axis motorattachment location, a second z-axis motor attachment location, a firstlinear track extending along the z-axis and a second linear trackextending along the z-axis; a first z-axis motor attached to the bodystructure at the first z-axis motor attachment location, the firstz-axis motor configured to exact movement in the z-axis; a second z-axismotor attached to the body structure at the second z-axis motorattachment location, the second z-axis motor configured to exactmovement in the z-axis; a first body attached to the first linear trackand operably connected to the first z-axis motor such that the firstbody moves along the first linear track when the first z-axis motor isactuated; a second body attached to the second linear track and operablyconnected to the second z-axis motor such that the second body movesalong the second linear track when the second z-axis motor is actuated;a first theta motor operably connected to the first body; a second thetamotor operably connected to the second body; a first receiving locationoperably connected to the first body, the first receiving locationconfigured to receive a pick-and-place spindle, wherein the first thetamotor is configured to rotate a pick-and-place spindle received in thefirst receiving location; and a second receiving location operablyconnected to the second body, the second receiving location configuredto receive a pick-and-place spindle, wherein the second theta motor isconfigured to rotate a pick-and-place spindle received in the secondreceiving location, wherein the first receiving location and the secondreceiving location are spaced apart along the x-axis and located at asame location along the y-axis, wherein the first z-axis motor and thesecond z-axis motor are spaced apart along the x-axis and spaced aparton the y-axis.

According to another embodiment, a pick-and-place dispensing headcomprises: a body structure having a z-axis motor attachment locationand a linear track; a z-axis motor attached to the body structure at theaxis motor attachment location, the z-axis motor configured to exactmovement in a z-axis; a body attached to the linear track and operablyconnected to the z-axis motor such that the body moves along the lineartrack when the z-axis motor is actuated; a theta motor operablyconnected to the first body; a receiving location operably connected tothe body, the receiving location configured to receive a pick-and-placespindle such that the pick-and-place spindle is configured to moverelative the body in the z-axis when an upward z-axis force is appliedto the pick-and-place spindle, the receiving location including a springmechanism configured to return the spindle to a start position afteractuation by the z-axis motor, and wherein the first theta motor isconfigured to rotate a pick-and-place spindle received in the firstreceiving location and remain engaged with the pick-and-place spindleduring z-axis movement of the pick-and-place spindle; and an opticaldetector extending from the first body configured to detect upwardz-axis movement of a received pick-and-place spindle relative to thebody.

BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments of this invention will be described in detail, withreference to the following figures, wherein like designations denotelike members, wherein:

FIG. 1 depicts a perspective view of an assembly machine in accordancewith one embodiment;

FIG. 2A depicts a perspective view of the assembly machine of FIG. 1with covers removed in accordance with one embodiment;

FIG. 2B depicts a perspective view of a portion of the assembly machineof FIG. 2A enlarged at circle A in accordance with one embodiment;

FIG. 3 depicts a perspective view of a spindle module in accordance withone embodiment;

FIG. 4 depicts a perspective view of a body structure of the spindlemodule in accordance with one embodiment;

FIG. 5 depicts a front view of the body structure of FIG. 4 inaccordance with one embodiment;

FIG. 6 depicts a partially exploded view of the spindle module of FIG. 3in accordance with one embodiment;

FIG. 7A depicts a side view of the spindle module of FIG. 3 inaccordance with one embodiment;

FIG. 7B depicts a cross sectional view of the spindle module of FIG. 7Ataken at arrows A-A in accordance with one embodiment;

FIG. 8 is a perspective view of a spindle nozzle in accordance with oneembodiment;

FIG. 9 is a side view of the spindle nozzle of FIG. 12 in accordancewith one embodiment;

FIG. 10 depicts a side cutaway view of the spindle module of FIG. 3 inaccordance with one embodiment;

FIG. 11 depicts a front view of the spindle module of FIG. 3 with thefirst z-axis motor actuated in accordance with one embodiment;

FIG. 12A depicts a perspective view of the spindle module of FIG. 3 withthe first z-axis motor actuated in accordance with one embodiment;

FIG. 12B depicts a perspective view of a portion of the spindle moduleof FIG. 12A enlarged at circle B in accordance with one embodiment;

FIG. 13A depicts a perspective view of the spindle module of FIG. 3 withthe first z-axis motor actuated in accordance with one embodiment;

FIG. 13B depicts a perspective view of a portion of the spindle moduleof FIG. 13A enlarged at circle C in accordance with one embodiment;

FIG. 14 is a perspective view of a spindle bank in accordance with oneembodiment; and

FIG. 15 is a perspective view of the spindle bank of FIG. 14 with aplurality of spindle modules attached in accordance with one embodiment.

DETAILED DESCRIPTION

A detailed description of the hereinafter described embodiments of thedisclosed apparatus and method are presented herein by way ofexemplification and not limitation with reference to the Figures.

Referring to FIG. 1, an assembly machine 10 is shown. The assemblymachine 10 is a pick-and-place machine configured to assemble printedcircuit boards (PCB's) in the embodiment shown. For example, theassembly machine may be an advanced packaging assembly machine, acomponent assembly machine, or the like. In other embodiments, thefeatures described herein may be applied to various other assemblymachines such as odd form assembly machines (OFA), or the like. TheAssembly machine 10 includes a frame 12 providing structure a body 14having covers 16 a, 16 b. The frame 12 may include a plurality of legsupon which the assembly machine 10 is configured to stand. The assemblymachine 10 includes a plurality of feeder banks 18 a, 18 b. A pluralityof feeders 20 are disposed (shown in FIG. 2A), attached, or otherwisemounted to each of the feeder banks 18 a, 18 b. The feeders 20 may eachinclude a plurality of electronic components that the assembly machine10 is configured to pick-and-place onto a PCB to assemble or at leastpartially assemble the PCB. The assembly machine 10 further includes aboard handling opening 22. A board handling track 24 may extend withinthe body 14 of the assembly machine 10 extending between the opening 22and another opening on the opposing side of the assembly machine (notshown). The board handling track 24 may be configured to receive a PCBor another unfinished product and transport the PCB to a placementlocation within the body of the assembly machine 10 for assembly. Theassembly machine 10 is shown further including operator interface andcontrol displays 26 a, 26 b, one on each side. The display 26 may beconfigured to receive user or operator inputs and display informationnecessary or useful to a user or operator. While the features of theassembly machine 10 shown are one exemplary embodiment, aspects of theinvention described herein are applicable to various other types ofassembly machines as will be apparent to those skilled in the art.

Referring now to FIG. 2A, the assembly machine 10 is shown with thecovers 16 a, 16 b removed exposing an interior 28 of the assemblymachine 10. The assembly machine 10 includes two additional feeder banks18 c, 18 d disposed on the opposite side of the body 14 as the feederbanks 18 a, 18 b. The board handling track 24 may be located between thefeeder banks 18 a, 18 b and 18 c, 18 d. The board handling track 24 maybe configured to provide an unfinished product such as a PCB to aplacement station 30 located along the track 24.

The assembly machine 10 may facilitate movement of components in threemovement axes: an x-axis, a y-axis and a z-axis. Hereinafter, the x-axismay be an axis extending parallel to the board handling track 24. They-axis may be perpendicular to the x-axis and the board handling track24. The z-axis may be an up and down or vertical axis. The assemblymachine 10 may include a plurality of movement axes 32, 34, 36, 38 forfacilitating movement in the x-axis and the y-axis. In particular, theassembly machine 10 may include a first movement axis 32 and a secondmovement axis 34 that are configured to facilitate movement in they-axis. The assembly machine 10 may include a third movement axis 36 anda second movement axis 38 that are configured to facilitate movement inthe x-axis. The first and the second movement axis 32 may extend along adepth of the machine between a first side 40 and a second side 42. Thefirst side 40 is the side of the assembly machine 10 proximate the firstand second feeder banks 18 a, 18 b. The second side 42 is the side ofthe assembly machine 10 proximate the third and fourth feeder banks 18c, 18 d. The third and fourth movement axes 36, 38 are shown connectedto the first and second movement axes 32, 34 and extend there between.During operation of the assembly machine 10, the third and fourthmovement axes 36, 38 are configured to each independently move along thefirst and second movement axes 32, 34 to provide for movement in they-axis. A spindle bank 100 a, 100 b is shown movably attached to each ofthe third and fourth movement axes 36, 38, respectively. The spindlebanks 100 a, 100 b may each be configured to move along the x-axis bymoving along the respective third and fourth movement axes 36, 38. Inother embodiments, the assembly machine 10 may be a single-moveable axismachine. For example, there may be a single x-axis and a single y-axisconnectable to the assembly machine, rather than two of each as shown inthe embodiment in the Figures.

With the movement axes 32, 34, 36, 38, the spindle banks 100 a, 100 bwithin the assembly machine 10 are configured for both x-axis and y-axisfreedom of operation within the interior 28. This allows the spindlebanks 100 a, 100 b to move back and forth to and from the feeder banks18 a, 18 b, 18 c, 18 d and the placement station 30. This isaccomplished by both the movement of the spindle banks 100 a, 100 balong the respective third and fourth movement axes 36, 38, and themovement of the third and fourth movement axes 36, 38 along the firstand second movement axes 32, 34. Other forms of x-axis and y-axismovement within the assembly machine 10 are contemplated and themovement axes shown are for exemplary purposes.

Referring now to FIG. 2B, a perspective view of a portion of theassembly machine 10 enlarged at circle A (from FIG. 2A) is shown. Theenlarged portion shows the spindle bank 100 a having a base 110 and abearing system 112. The base 110 may be a body, housing, structure orthe like. The base 110 may include a plurality of mount locations 114 a,114 b, 114 c, 114 d, 114 e, 114 f, 114 g, 114 h each configured toreceive a spindle module 200 a, 200 b, 200 c, 200 d, 200 e, 200 f, 200g, 200 h, respectively. The spindle modules described herein may bepick-and-place spindle modules particularly configured for receivingspindle and nozzle combinations that are configured to pick, place, orotherwise manipulate electronic components for printed circuit boardassembly and picking and placement processes. The spindle modulesdescribed herein may also be utilized for other assembly processes whereone or more rotatable and/or descendible manipulating spindles arenecessary to perform at least a portion of an assembly process forassembling an unfinished product.

The bearing system 112 may be a system that provides for movement of thespindle bank 100 a along the third movement axis 36. The bearing system112 may include wheels to facilitate movement between the spindle bank100 a and the movement axis 36. In other embodiment, the bearing system112 may include magnets to facilitate magnetic movement between thespindle bank 100 a and the third movement axis 36. The third movementaxis 36 may include a track structure on the underside (not shown) thatmay cooperate with a track structure bearing system of the spindle bank100 a. For example, the spindle bank 100 may include track runnerbearings configured to cooperate with a track of the third movement axis36. A motor or other movement creating mechanism may provide forcontrolled powered movement of the spindle bank 100 along the thirdmovement axis 36. The motor may be located on the spindle bank itself100, or may be located on the third movement axis 36. Thus, the spindlebank 100 may include one or more electrical ports, connectors or thelike to connect to an electrical system of the assembly machine 10 tothereby provide electrical power to the spindle bank 100. The spindlebank 100 may utilize this electricity to power a motor or otherwiseprovide motion, movement, or acceleration of the spindle bank 100relative to the third movement axis 36.

The mount locations 114 a, 114 b, 114 c, 114 d, 114 e, 114 f, 114 g, 114h may provide for modularity in the spindle bank 100 a such that thespindle bank 100 a may be operable with each of the spindle modules 200a, 200 b, 200 c, 200 d, 200 e, 200 f, 200 g, 200 h attached or with asingle one of the spindle modules. In other words, the spindle bank 100a may be operable no matter how many of the spindle modules 200 a, 200b, 200 c, 200 d, 200 e, 200 f, 200 g, 200 h are installed into the mountlocations 114 a, 114 b, 114 c, 114 d, 114 e, 114 f, 114 g, 114 h. If oneof the spindle modules 200 a, 200 b, 200 c, 200 d, 200 e, 200 f, 200 g,200 h breaks or is need of repair, the spindle bank 100 a may beoperable. Further, while the spindle modules 200 a, 200 b, 200 c, 200 d,200 e, 200 f, 200 g, 200 h shown are all the same or similar, the mountlocations 114 a, 114 b, 114 c, 114 d, 114 e, 114 f, 114 g, 114 h mayeach be configured to receive different types of spindle modules withdifferent types of spindles, nozzles and the like. The mount locations114 a, 114 b, 114 c, 114 d, 114 e, 114 f, 114 g, 114 h may each have thesame physical mounting properties such that the spindle modules 200 a,200 b, 200 c, 200 d, 200 e, 200 f, 200 g, 200 h may each include thesame mounting properties, making each module interchangeably attachableto any mount location. In other embodiments, the spindle bank 100 a mayinclude mount locations that have different physical attachmentproperties to provide for attachment of modules having differentattachment mechanisms or properties than other modules attachable inother mount locations on the spindle bank 100 a.

Referring now to FIG. 3, a spindle module 200 is shown. The spindlemodule may be the same as one of the spindle modules 200 a, 200 b, 200c, 200 d, 200 e, 200 f, 200 g, 200 h shown in FIG. 2B. The spindlemodule 200 is shown including a modular body structure 210. The modularbody structure may include a first body structure 212 and a second bodystructure 214 mounted or attached to the first body structure 212. Thesecond body structure 214 includes a first receiving location 216configured to receive a first spindle 300 a, and a second receivinglocation 218 configured to receive a second spindle 300 b.

The spindle module 200 further includes a first z-axis motor 220 and asecond z-axis motor 222, each mounted to the second body structure 214.The first z-axis motor 220 may be configured to move the first spindle300 a in the z-axis direction. Similarly, the second z-axis motor 222may be configured to move the second spindle 300 b in the z-axisdirection. The spindle module 200 further includes a first theta motor224 and a second theta motor 226. The first theta motor 224 may beconfigured to rotate the first spindle 300 a in a theta (θ) rotationalaxis. The second theta motor 226 may be configured to rotate the secondspindle 300 b in the theta (θ) rotational axis. The first and secondtheta motors 224, 226 may be configured to provide theta axis rotationin either directions. Thus, the spindle module 200 may provide formovement in the z-axis and rotational movement in the theta (θ)rotational axis. The spindle module 200 may provide for independentmovement for each of the first and second spindles 300 a, 300 b.

The spindle module 200 may further include an air distribution systemthat includes one or more valves 228, 230, first and second airdistribution ports 232, 234 (shown in FIGS. 12A and 13A), along with twoairflow tubes 236 (one shown), each providing vacuum generating airflowto the first and second spindles 300 a, 300 b. The air distributionsystem may further include a pneumatic connector 256 (one shown) on eachside. The first and second air distribution ports 232, 234 may each beconfigured to receive air from an air distribution system of theassembly machine 10 and deliver the received air to the first and secondspindles 300 a, 300 b. After receiving the air at the air distributionports 232, 234, internal airflow tubes (not shown) may provide thisairflow to the pneumatic connectors 256. The airflow tubes 236 mayconnect to the pneumatic connectors 256 by elongating the airflow tubesor using another tube that connects the pneumatic connectors 256 to theairflow tubes 236, respectively. In the embodiment shown, the firstvalve 228 is housed within a widened portion of the first body structure214, and may provide for air-kiss forward air pressure. The second valve230 is also shown to be housed within a widened portion of the firstbody structure 214, and may be a valve for providing vacuum pressure forpicking up a component with the first and second spindles 300 a, 300 b.

The spindle module 200 may have a first outer body 238 a and a secondouter body 238 b mounted to the first body structure 212 with severalscrews. The outer bodies 238 a, 238 b may be a first circuit board and asecond circuit board. As shown, the spindle module 200 includes anelectrical distribution system including a second circuit board assembly251 containing a plurality of electrical distribution ports 242 a, 242 bconfigured to receive electricity from the assembly machine 10 and/orthe spindle bank 100 a or 100 b when attached and deliver the receivedelectricity to the first and second z-axis motors 220, 222 and the firstand second theta motors 224, 226. When the spindle module 200 isattached to the assembly machine 10, each of the electrical distributionports 242 a and 242 b may be attached to electrical connectors of theassembly machine 10 or spindle bank 100 a or 100 b.

In one embodiment, the ports 240 a, 240 b may be configured to deliverelectricity from the distribution ports 242 a and 242 b to the circuitboard assembly 238 a and 238 b and to electrical connectors 252, 254,257. It should be understood that duplicate electrical connectors to theelectrical connectors 252, 254 and 257 are found on the opposite side ofthe outer body 238 a. Thus, electricity may travel through the port 242a through 240 a and 238 a and through the electrical connector 257, andthrough a cable (not shown) to the first z-axis motor 220. Similarly,electricity may travel through the port 242 a, through 240 a and 238 athrough the electrical connector 252 and through a cable (not shown) tothe first theta motor 224. Connector 254 may be used to connect to aspindle module optical detector 550 (described herein below, cable notshown) to the motion control chip 250 located on 238 a. This electricalarrangement may be duplicated on the other side with respect to theprinted circuit board second outer body 238 b.

The spindle module 200 may include one or more mechanical attachmentmechanisms to facilitate attachment of the spindle module 200 to theassembly machine 10, for example to a spindle bank such as one of thespindle banks 100 a, 100 b. In the embodiment shown, the mechanicalattachment mechanisms comprise a first threaded screw 246 a and a secondthreaded screw 246 b. In one embodiment, the mechanical attachmentmechanism may be capable of attachment with only a non-powered hand toolsuch as a screw driver, Allen wrench, wrench, or the like. In theembodiment shown, the first and second threaded screws 246 a, 246 b maybe turned by an Allen wrench at bolt heads 248 a, 248 b (shown in FIG.5). Further, the tightening of the threaded screws 246 a, 246 b may bethe only procedure or step required to attach the spindle module 200 toone of the spindle banks 100 a, 100 b. Similarly, the loosening of thethreaded screws 246 a, 246 b may be the only procedure or step requiredto unattach or remove the spindle module 200 from one of the spindlebanks 100 a, 100 b.

The attachment of the spindle module 200 may be completed, executed orperformed such that the air distribution ports are connectable toreceive air from the assembly machine 10 and/or the spindle bank 100 aor 100 b, and the electrical distribution port is configured to receiveelectricity from the assembly machine 10 and/or the spindle bank 100 aor 100 b. The spindle module 200 may not be attachable directly to anymovement axis of the assembly machine 10, such as the first, second,third or fourth movement axes 32, 34, 36, 38. Instead, the spindlemodule 200 may be attachable to one of the spindle banks 100 a, 100 bwhich in turn may be attachable to one or more of the first, second,third or fourth movement axes 32, 34, 36, 38.

The spindle module 200 may further include a first motion control chip250 attached to the first body structure 212 proximate the second bodystructure 214 and the motors 220, 222, 224, 226. An opposite side of thefirst body structure 212 may include a second motion control chip (notshown) in a mirrored location as the first motion control chip 250. Thefirst motion control chip 250 may each be configured to control thefirst z-axis motor 220 and the first theta motor 224. The motion controlchip 250 may thus be a dedicated control chip, processor, or the like,configured to control only one of the two spindles 300 a, 300 bcontained in the spindle module 200, in particular the first spindle 300a. The second motion control chip may be a dedicated control chip,processor, or the like configured to control the second spindle 300 b.Each of the first motion control chip 250 and the second motion controlchip may be configured to control speed, acceleration and position ofthe respective first and second z-axis motors 220, 222 and the first andsecond theta motors 224, 226. Further, each of the first motion controlchip 250 and the second motion control chip may be configured to createan independent and/or separate motion control profile for each of thefirst and second spindles 300 a, 300 b, respectively.

Referring now to FIGS. 4 and 5, a perspective view and side view,respective, of the second body structure 214 is shown prior toattachment with the first body structure 212. The second body structure214 includes a middle structural portion 258, an upper structuralportion 260 and a lower structural portion 262. The second bodystructure 214 may be a machined metallic component consistent with thedimensions shown. The second body structure 214 may be configured toreceive for attachment the first and second z-axis motors 220, 222, andmay include the support structure to allow for moveable attachment alongthe z-axis of the first and second theta motors 224, 226, as describedin more detail herein below.

The middle structural portion 258 may include an opening 263 or boreconfigured to receive the second threaded screw 246 b and the head 248 bthereof. The middle structural portion 258 may include a square orrectangular cross section extending in the direction of the opening 263and surrounding the opening 263. A back end of the middle structuralportion 258 may include extending support flanges 264 a, 264 bconfigured for supporting the second body structure 214 when mounted tothe first body structure 212.

The upper structural portion 260 extends upward from the middlestructural portion 258. The upper structural portion 260 includes adepth extending from a front end 269 along the y-axis. The upperstructural portion 260 includes an upper rectangular removed portion 274configured to reduce the weight of the second body structure 214. Theupper structural portion 260 includes a first z-axis motor mount face266 and a second z-axis motor mount face 268. The first z-axis motormount face 266 is shown flush to the front end 269 of the upperstructural portion 260 while the second z-axis motor mount face 268extends from a middle point along the depth of the upper structuralportion, the middle point being closer to the front end 269 than theopposing rear end. The first z-axis motor mount face 266 and the secondz-axis motor mount face 268 may be spaced apart along both the x-axisand the y-axis. Further, the first z-axis motor mount face 266 may befacing a first direction while the second z-axis motor mount face 268may be facing a second direction that is opposite the first direction.The first and second z-axis mount faces 266, 268 may each include aremoved portion 276 a, 276 b configured to reduce the weight of thesecond body structure 214.

In one embodiment, the first and second mount faces 266, 268 may belocated such that when mounted the vertical z-axes of first and secondz-axis motors 220, 222 are spaced at least 18 mm apart. In otherembodiments, the first and second mount faces 266, 268 may be locatedsuch that when mounted the vertical z-axes of first and second z-axismotors 220, 222 are spaced no more than 18 mm apart. In yet otherembodiments, the first and second mount faces 266, 268 may be locatedsuch that when mounted the vertical z-axes of the first and secondz-axis motors 220, 222 are spaced at least 16 mm apart. In oneembodiment, the first and second mount faces 266, 268 may be locatedsuch that when mounted the vertical z-axes of the first and secondz-axis motors 220, 222 are spaced at least 18 mm apart in total and atleast 10 mm apart along the x-axis. Thus, the first and second mountfaces 266, 268 may be located such that when mounted the vertical z-axesof the first and second z-axis motors 220, 222 are spaced on a diagonalrelative the x-axis and the y-axis.

Extending to the top of the upper structural portion 260 is an upperstanchion 270, post, or the like configured to provide for a secondattachment location. The upper stanchion 270 may include another opening272 or bore configured to receive the first threaded screw 246 a and thehead 248 a for attachment of the combined modular body structure 210 tothe spindle bank 100 a, 100 b.

The lower structural portion 262 extends downward from the middlestructural portion 258. The lower structural portion 262 includes adepth extending from a front end 277 along the y-axis. The lowerstructural portion 262 includes a lower rectangular removed portion 273configured to reduce the weight of the second body structure 214. Thelower structural portion 262 may be a U-shaped structure extending fromthe middle portion 258. The front end 277 of the U-shaped structure ofthe lower structural portion 262 includes a first linear track 278mounted or otherwise attached to a front surface and a second lineartrack 280 mounted or otherwise attached to an opposing back surface suchthat the first linear track 278 and the second linear track 280 eachextend along the z-axis.

A first body 282 is shown attached to the first linear track 278 and asecond body 284 is shown attached to the second linear track 280. Asshown in FIGS. 7-8 and described herein below, the first body 282 isoperably connected to the first z-axis motor 220 such that the firstbody 282 moves along the first linear track 278 when the first z-axismotor 220 is actuated. Similarly, the second body 284 is operablyconnected to the second z-axis motor 222 such that the second body 284moves along the second linear track 280 when the second z-axis motor 222is actuated. The first and second bodies 282, 284 may each be linearbearing systems configured to integrate with the first and second lineartracks 278, 280, respectively. In one embodiment, the first and secondbodies 282, 284 may be configured to slidably move along the first andsecond linear tracks 278, 280, respectively. In other embodiments, thefirst and second bodies 282, 284 may house rollers or wheels configuredto facilitate movement along the first and second tracks 278, 280. Toattach the first and second bodies 282, 284 to the first and secondtracks 278, 280, respectively, the first and second bodies 282, 284 maybe slid into the track from the bottom. Once the first and second bodies282, 284 are operably connected to the first and second z-axis motors220, 222, respectively, the downward z-axis motion of the first andsecond bodies 282, 284 may be restricted by the movement of the firstand second z-axis motors 220, 222 in order to securably attach the firstand second bodies 282, 284 onto the first and second tracks 278, 280.

Referring now to FIG. 6, a partially exploded view of the second bodystructure 214 is shown having the first z-axis motor 220 and the secondz-axis motor 222 already attached, the first theta motor 224 and thesecond theta motor 226 disassembled from the second body structure 214,and the first and second spindles 300 a, 300 b disassembled from thefirst and second receiving locations 216, 218, respectively. A thirdbody structure 286 is shown attached to the first body 282 and a fourthbody structure 288 is shown attached to the second body 284. The thirdand fourth body structures 286, 288 are shown attached to the first andsecond bodies 282, 284 through screws or bolts 290 a, 290 b which may bethreadably received by openings 291 a, 291 b (shown in FIG. 4) in thefirst and second bodies 282, 284. The third and fourth body structures286, 288 may be configured for attaching the first and second thetamotors 224, 226 to the movable first and second bodies 282, 284. In thismanner, the first and second theta motors 224, 226 may be operablyconnected to the first and second bodies 282, 284, respectively. Thethird and fourth body structures 286, 288 may include the first andsecond receiving locations 216, 218, respectively for receiving thefirst and second spindles 300 a, 300 b. Further, the third and fourthbody structures 286, 288 may include a location at the top thatinterfaces with and/or otherwise attaches to an extending portion of thez-axis motor 220, 222.

Each of the third and fourth body structures 286, 288 may include atheta motor attachment location 292, 294 configured to receive the firstand second theta motors 224, 226, respectively. The theta motorattachment locations 292, 294 may each be semi-circular in shape. Thetheta motor attachment locations 292, 294 may be offset from thereceiving locations 292, 294, respectively, such that motor drive gears295, 296 of the first and second theta motors 224, 226 may be meshedwith theta gears 310 of the spindle 300 a, 300 b. In one embodiment, thefirst receiving location 216 and the second receiving 218 locationspaced apart by a spacing S equal to or less than 10 mm. In otherembodiments, the spacing S may be equal to or less than 8 mm. In stillother embodiments, the spacing may be equal to or less than 12 mm.

Referring now to FIGS. 7A and 7B, a mechanism and method for connectingthe first and second linear tracks 278, 280 to the second body structure214 is shown. In particular, FIG. 7A shows a side view of the spindlemodule 200. FIG. 7B shows a cross sectional view of the second bodystructure 214 of the spindle module 200 at a location where the firstand second linear tracks 278, 280 are connected, taken at arrows A-A. Asshown in FIG. 7B, the first linear track 278 and the second linear track280 are attached to the lower structural portion 262 of the second bodystructure 214 of the modular body structure 210 of the spindle module200 with a set screw 297 extending between a first nut 298 a and asecond nut 298 b. The set screw 297 may include exterior threads asshown. Each of the first and second nuts 298 a, 298 b may include aninternally threaded nut body 299 a, 299 b configured to receive theexterior threads of the set screw 297.

The first and second linear tracks 278, 280 may include bores 289 a, 289b, configured to receive a heads 293 a, 293 b, respectively, of thefirst and second nuts 298 a, 298 b. In particular, the first lineartrack 278 may include the first bore 291 a configured to receive thefirst head 293 a of the first nut 298 a when tightened such that thefirst nut 298 a does not interfere with movement of the first body 282on the first linear track 278. Similarly, the second linear track 280may include a second bore 291 b configured to receive the second head293 b of the second nut 298 b when tightened such that the second nut293 b does not interfere with movement of the second body 284 on thesecond linear track 280.

To connect the first and second linear tracks 278, 280 to the secondbody structure 214, the process includes inserting the set screw 297into an opening in each of the first and second linear tracks 278, 280while aligned with an opening of the second body structure 214, theninserting the nuts 298 a, 298 b such that the internally threaded nutbody 299 a, 299 b engages with the external threads of the set screw297. Next, the process includes tightening the first and second nuts 298a, 298 b until tight. In one embodiment, only a single set screw and nutcombination may be required to fully attach the first and second lineartracks 278, 280. In another, a second set screw may extend between athird nut and a fourth nut at a spaced apart location from the first setscrew 297, the first nut 298 a, and the second nut 298 b. An embodimenthaving two set screws is shown in the Figures (e.g. FIG. 4) where twoheads 293 a of the set screws are shown recessed in the track, one at atop of the linear track 278 and one at the bottom of the linear track278.

Referring now to FIGS. 8 and 9, a spindle 300 is shown. In particular,FIG. 8 shows a perspective view of the spindle 300 and FIG. 9 shows aside view of the spindle. The spindle 300 may include the same featuresas the spindles 300 a, 300 b. The spindle 300 includes a theta gear 310,a shaft 312 and a nozzle tip 314. The spindle 300 may extend between afirst lower end 328 and a second upper end 330.

The spindle 300 may be considered a spindle-nozzle combination. Thenozzle tip 314 is configured to contact an electronic component formanipulation of the electronic component. Additionally, the spindle 300may include the rotatable shaft 312 and the theta gear 310 to facilitaterotation. The spindle 300 may be configured for interchangeability on,or removably attachable to, a dispensing or pick-and-place head (such asthe spindle bank 100 and the spindle module 200 combination). Thespindle 300 may be found in a nozzle bank of the assembly machine 10when it is not attached to the spindle module 200 and/or spindle bank100.

The spindle 300 may be configured to provide vacuum suction to theelectronic component through the nozzle tip 314 to allow for the pickingup, or other manipulation, of electronic components by the nozzle tip314. To provide airflow or a vacuum force to the nozzle tip 314, theshaft 312 may include an outer body 316 having a hollow interior 318.The spindle 300 may be configured to provide an airkiss outward airflowthrough the nozzle tip 314 to the electronic component to facilitateplacement of electronic components. In other embodiments, other types ofnozzles may be contemplated for the spindle 300, such as nozzlesconfigured to provide a material to an unfinished product.

The theta gear 310 may be disposed onto the shaft 312. The theta gear310 may include a plurality of teeth 320 evenly disposed about thecircumference of the theta gear 310. The teeth 320 of the theta gear 310may be configured to engage with a theta motor such as one of the thetamotors 224, 226. For example, the teeth 320 may be configured to engagewith a motor drive gear, such as one of the motor drive gears 295, 296,of the theta motors 224, 226.

The shaft 312 may be cylindrical in shape. The theta gear 310 may besecured to, attached to, or otherwise integrated with, the shaft 312such that rotation of the theta gear 310 by a motor drive gear alsorotates the shaft 312. In some embodiments, the theta gear 310 may be aseparately manufactured component from the shaft 312. The theta gear 310may include a circular inner opening configured to receive the shaft312.

The outer body 316 of the rotatable shaft 312 includes a first opening322 configured to receive airflow into the hollow interior 318. Forexample, the airflow tube 236 of the spindle module 200 may beconfigured to deliver airflow through the first opening 322 into thehollow interior. The outer body 316 of the rotatable shaft 312 includesa second opening 324 configured to receive airflow into the hollowinterior 318. The airflow tube 236 of the spindle module 200 may beconfigured to deliver airflow through the second opening 324 into thehollow interior. The second opening 324 may be disposed on an oppositeside of the rotatable shaft 312 than the first opening 322. While theembodiment shown in FIGS. 8 and 9 includes two openings 322, 324, moreor less openings are contemplated. As shown, the each of the first andsecond openings 322, 324 may be disposed about the outer body 316 of therotatable shaft 312 at a point along a length of the shaft.

The theta gear 310 may further include an upper surface 326 facing thesecond upper end 330, and a lower surface 332 facing the first lower end328. The theta gear 310 may include an outer circumference with theteeth 320 disposed along the outer circumference. The theta gear 310 mayfurther include a circumferential ridge 334 extending from the uppersurface 326 toward the first lower end 328. The circumferential ridge334 may be a ring, protrusion, or the like, and may be located betweenthe outer circumference of the theta gear 310 and the shaft 312.

The theta gear 310 may further include a lower base 336 and an upperbase 338. The lower base 336 may extend from the lower surface 332toward the first lower end 328 of the spindle 300. The lower base 336may be located proximate the opening of the theta gear 310 and mayextend along a length of the opening of the theta gear 310 and along alength of the shaft 312. The lower base 336 and the upper base 338 maybe configured to provide support for the attachment of the theta gear310 to the shaft 312.

In one embodiment, the shaft 312 may be made of a magnetic material tofacilitate magnetic attachment of the spindle 300 to a receivinglocation, such as one of the receiving locations 216, 218, of adispensing head or pick-and-place head such as the spindle module 200and/or the spindle bank 100. The magnetic material may provide forremovable attachment of the spindle 300 to the dispensing head orpick-and-place head, as described hereinbelow.

The spindle 300 is shown as a spindle-nozzle combination that includes atoothed arrangement for being driven by a tooth drive gear. However, thespindle 300 may also be a spindle-nozzle combination where the thetagear is a magnetic gear rather than a toothed gear. A magnetic thetagear may be driven by a magnetic theta motor. Whatever drive mechanismutilized the spindle 300 may include a nozzle and an integrated means toprovide for rotation of the nozzle.

Referring now to FIG. 10, a side cutaway view of the spindle module 200of FIG. 3 is shown. In particular, FIG. 10 shows the attachment of thefirst z-axis motor 220 to the third body structure 286. It should beunderstood that the features that are described hereinbelow as shownwith respect to the first z-axis motor 220 and the third body structure286 may be applicable to the second z-axis motor 222 connecting to thefourth body structure 288.

Each of the first and second z-axis motors 220, 222 includes a movableshaft 516 a, 516 b, respectively, each configured to move relative tothe body of the motor. Each of the first and second z-axis motors 220,222 includes a spring 518 a, 518 b proximate a cap 520 a, 520 b. Thesprings 518 a, 518 b may be configured to return the movable shaft 516a, 516 b to the start position after actuation by the z-axis motor 220,222. The top end of each of the shafts 516 a, 516 b is connected to therespective caps 520 a, 520 b by a threaded feature of the cap beinginserted into a threaded bore of the shafts 516 a, 516 b. A threaded setscrew 514 may be located at the bottom of each of the shafts 516 a, 516b connecting the shaft to the third and fourth body structures 286, 288,respectively. Thus, when the z-axis motors 220, 222 are actuated and theshafts 516 a, 516 b displace downward, so do the respective attachedbody structures, which includes the respective nozzles 300 a, 300 b, andthe respective theta motors 224, 226.

Furthermore, the first receiving location 216 is shown after havingreceived the first spindle 300 a into a bore of the first receivinglocation 216. The first receiving location 216 and the shaft 312 of thefirst spindle 300 a may include a relatively tight tolerance to allowfor z-axis sliding and rotation of the shaft 312 without other movement.The shaft 312 of the first spindle 300 a may be magnetic and may beattracted to a magnet 510 located or disposed within the third bodystructure 286. This may create a holding force to retain the firstspindle 300 a within the first receiving location 216. However, thisholding force may be overcome by a greater force if it is desired forthe first spindle 300 a to be removed from the first receiving location216. In this manner, the first spindle 300 a may be removably attachableto the first receiving location 216. As shown a spindle spring 512 maybe housed within the third body structure 286. This spindle spring 512may provide a small amount of spring movement at the moment of pickupand/or placement of a component by the spindle 300 a, when the spindle300 a is resisted by the upward force from the unmovable feeder bank(during pickup) and unfinished product or PCB (during placement. Inother embodiments not shown, the spindle spring 512 may be replaced by amagnet that provides a resistive magnetic force on a correspondingmagnet of the spindle 300 a.

FIG. 11 depicts a front view of the spindle module 200 with the firstz-axis motor 220 actuated. As shown, the second z-axis motor 222 remainsin the upward and non-actuated position. When actuated, the shaft 516 aand spring 518 a are compressed. When actuated, the shaft 518 a thenprotrudes from the bottom of the body of the z-axis motor 220. Anattachment location 522 a between the shaft 518 a and the third bodystructure 286 is thereby moved down, moving down the first body 282, thefirst theta motor 224, the first receiving location 216 and the firstspindle 300 a. Meanwhile, an attachment location 522 b between the shaft518 b and the fourth body structure 288 remains stationary, along withthe second body 284, the second theta motor 226, the second receivinglocation 218 and the second spindle 300 b.

FIG. 12A depicts a perspective view of the spindle module 200 with thefirst z-axis motor 220 actuated and having a circle B drawn around aportion of the spindle 300 a. FIG. 12B depicts a perspective view of aportion of the spindle module 200 enlarged at the circle B. The enlargedview from FIG. 12B shows a spindle module optical detector 550 extendingfrom the third body structure 282 attached to the first body 282. Theoptical detector 550 may be configured to detect upward movement of thereceived first spindle 300 a relative to the first body 282 and thethird body structure 282. It should be understood that the spindlemodule 200 may include a second optical detector positioned in the samemanner detecting movement of the second received spindle 300 b.

As shown in FIG. 12B, the spindle 300 a is in a resting downwardposition before the spindle 300 a contacts an electronic component forpicking up, or before the spindle 300 a contacts the PCB or otherunfinished product during placement. During this resting position, theteeth 320 of the spindle 300 a mesh with the teeth of the first thetamotor drive gear 295. Further, the circumferential ridge 334 of thefirst spindle 300 a does not extend into an opening 552 located betweena first end 554 and a second end 556 of the optical sensor 550. Thefirst end 554 of the optical sensor 550 may include an optical lightbeam generator 558 and the second end 556 of the optical sensor 550 mayinclude an optical light detector. When the circumferential ridge 334 ispositioned in the opening 552, the circumferential ridge 334 may breakthe beam. This may be configured to immediately detect when touchdownhas occurred during pickup and/or placement.

FIG. 13A depicts a perspective view of the spindle module 200 with thefirst z-axis motor 220 actuated and having a circle C drawn around aportion of the spindle 300 a. FIG. 13B depicts a perspective view of aportion of the spindle module 200 enlarged at circle C. As shown in FIG.13B, the spindle 300 a has now been moved upward relative to the firstbody 282 and the third body structure 282. Thus, the circumferentialridge 334 is positioned in the opening 552, thereby breaking the beam ofthe optical sensor 550. It should further be noted that the first thetamotor drive gear 295 includes a height that is large enough to maintaincontact with the teeth 320 of the nozzle 300 a during motion of thenozzle 300 a relative to the first theta motor drive gear 295. In oneembodiment, the first theta motor drive gear 295 may include a heightthat is larger than the maximum movement allowable between the spindle300 a and the first body 282 and the third body structure 282.

Referring first to FIG. 14, the spindle bank 100 having a single one ofthe spindle modules 200 attached. The spindle bank 100 includes the base110 and the mounting locations 114 a, 114 b, 114 c, 114 d, 114 e, 114 f,114 g, 114 h. In the embodiment shown, the base 110 includes eight ofthe mounting locations 114 a, 114 b, 114 c, 114 d, 114 e, 114 f, 114 g,114 h. In other embodiments, more or less mounting locations arecontemplated. For example, a spindle bank may have as little as a singlemounting location, or as many mounting locations as would, when attachedto the spindle bank 100, span across half the width of the assemblymachine, minus half the width of the intended unfinished product theassembly machine is intended to at least partially assemble. Such anarrangement would enable even the left and rightmost spindles in thespindle module to reach each point along the x-axis of the unfinishedproduct.

Each of the plurality of mount locations 114 a, 114 b, 114 c, 114 d, 114e, 114 f, 114 g, 114 h are configured to receive a mountable spindlemodule, such as the mountable spindle module 200 as shown. The spindlebank 100, when combined with one or more spindle modules 200 may be adispensing head or pick-and-place head for the assembly machine 10.Unlike typical dispensing heads and pick-and-place heads, the spindlebank 100 may provide a modular design for simple mechanical attachmentand removal of individual modular spindle modules, such as the spindlemodule 200. The modular nature of the spindle attachment may provide forsimpler maintenance when a spindle assembly needs repair. Further, whilethe spindle module 200 was described hereinabove as an example, variousother spindle modules may fit into the spindle bank 100, such as thespindle module 500, shown in FIG. 15. The modularity of the spindle bank100 and spindle module combination may provide flexibility to thesystem. The dispensing head defined by the spindle bank 100 and thespindle modules 200, 500 can be easily reconfigured with various spindlemodules in whatever configuration needed by an assembly process.

In the embodiment shown, the center of each of the mount locations 114a, 114 b, 114 c, 114 d, 114 e, 114 f, 114 g, 114 h may be spaced lessthan 25 mm apart. In other embodiments, the center of each of the mountlocations 114 a, 114 b, 114 c, 114 d, 114 e, 114 f, 114 g, 114 h may bespaced less than 20 mm apart. Any spacing is contemplated for the mountlocations 114 a, 114 b, 114 c, 114 d, 114 e, 114 f, 114 g, 114 h, but itmay be difficult but desirable to reduce the spacing by making each ofthe spindle modules 200 as thin as possible in order to reduce the sizeand weight of the spindle bank 100. The above described structure of thespindle module includes various features that provide for thin spindlemodules 200 such as the spacing of the z-axis motors 220, 222, thefeatures of the modular body structure 210, and the like.

The spindle bank 100 includes a bearing system 112 comprising a firstbearing 116 and a second bearing 118 for attaching the spindle bank 100to the movement axis of an assembly machine, such as the third movementaxis 36 or the fourth movement axis 38. The bearing system 112 maycooperate with a track found in the movement axis 36, 38 of the assemblymachine 10. In other embodiments, the bearing system 112 of the spindlebank 100 may include wheels or balls to facilitate movement (not shown).In other embodiments, the bearing system 112 may include other shapedchannels for integrating with a track system. In still others, thespindle bank 100 may include a powered bearing system that uses wheelsor magnetism to move the spindle bank 100 along the attached movementaxis. In others, the axis includes the movement system and the spindlebank 100 is unpowered for the purposes of movement but instead attachesto the axis and is moved by the movement system powered by the axis. Insome embodiments, a permanent magnet and coil system may be utilized inwhich the spindle bank 100 acts as either the permanent magnet(s) or themoveable coil(s), and the axis acts as the other of the permanentmagnet(s) or the movable coil(s). The spindle bank 100 may include anysystem for movably attaching the spindle bank 100 to one or more axisfor movement.

The spindle bank 100 further includes an air distribution systemincluding a first inlet 122 and a second inlet 124. The first inlet 122and the second inlet 124 may each be connected to a tube or other airdelivery system from the assembly machine. A channel may extend from thefirst air inlet 122 with various air outlets 126 a, 126 b, 126 c, 126 d,126 e, 126 f, 126 g configured to each deliver air to an airdistribution port, such as the first air distribution port 232 of thespindle module 200. Similarly, a channel may extend from the second airinlet 124 with various air outlets 128 a, 128 b, 128 c, 128 d, 128 e,128 f, 128 g configured to each deliver air to an air distribution port,such as the second air distribution port 234 of the spindle module 200.It should be understood two air outlets of the spindle bank 100 arehidden by the attached spindle module 200 in the embodiment shown inFIG. 14. In this manner, the plurality of mount locations 114 a, 114 b,114 c, 114 d, 114 e, 114 f, 114 g, 114 h may each be configured todeliver air to each of the mountable spindle modules when the modulesare mounted.

The spindle bank 100 may further include a power delivery system todelivery electrical power and/or signals to each of the plurality ofmount locations 114 a, 114 b, 114 c, 114 d, 114 e, 114 f, 114 g, 114 h.The power delivery system is shown including a set of electricalconnectors 132. The set of electrical connectors 132 may be configuredto connect to the electrical distribution ports 242 a, 242 b of each ofthe spindle modules 200. The spindle bank 100 may include one or moreelectrical input connectors (not shown) to provide electrical powerand/or other signals to the spindle bank 100 that are wired to theelectrical connectors 130, 132 disposed at the plurality of mountlocations 114 a, 114 b, 114 c, 114 d, 114 e, 114 f, 114 g, 114 h.

Each of the plurality of mount locations 114 a, 114 b, 114 c, 114 d, 114e, 114 f, 114 g, 114 h may include a first threaded attachment location134 configured to receive the first threaded screw 246 a of the spindlemodule 200. Each of the plurality of mount locations 114 a, 114 b, 114c, 114 d, 114 e, 114 f, 114 g, 114 h may include a second threadedattachment location 136 configured to receive the second threaded screw246 b of the spindle module 200. The first threaded attachment locations134 and the second threaded attachment locations 136 may each bethreaded bores. Thus, as described above, each spindle module 200 may bemounted and removed from the spindle bank 200 by the application orremoval of two threaded screws. A hand tool, such as a screwdriver,Allen wrench, wrench, or the like may be the only tool necessary forattachment of the spindle modules 200 to the spindle bank 100.

FIG. 15 shows a plurality of spindle modules 200 a, 200 b, 200 c, 200 d,200 e, 200 f, 200 g attached, along with the spindle module 500 that isdifferent from the spindle modules 200 a, 200 b, 200 c, 200 d, 200 e,200 f, 200 g. Thus, the plurality of mount locations 114 a, 114 b, 114c, 114 d, 114 e, 114 f, 114 g, 114 h includes a first mount locations114 a configured to receive a first mountable spindle module 500. Theplurality of mount locations 114 a, 114 b, 114 c, 114 d, 114 e, 114 f,114 g, 114 h may include second mount locations 114 b, 114 c, 114 d, 114e, 114 f, 114 g, 114 h each configured to receive a second mountablespindle module 200. In some embodiments, the first mount location 114 aand the second mount locations 114 b, 114 c, 114 d, 114 e, 114 f, 114 g,114 h may be structurally the same. In other embodiments, the spindlebank 100 may include structural differences between mount locations.Thus, the first mountable spindle module 500 is different than thesecond mountable spindle modules 200 a, 200 b, 200 c, 200 d, 200 e, 200f, 200 g. For example, the first mountable spindle module 500 includes asingle spindle and nozzle, while each of the second mountable spindlemodules 200 a, 200 b, 200 c, 200 d, 200 e, 200 f, 200 g include twospindle and nozzles. In accommodating different spindle modules, thefirst mount location 114 a may include at least one different physicalproperty than the second mount locations 114 b, 114 c, 114 d, 114 e, 114f, 114 g, 114 h. Spindle banks accommodating various different spindlemodules with differences in features or physical properties at the mountlocations are contemplated.

While not shown, it is also contemplated that the spindle bank 100includes one or more motion control chips for each of the plurality ofmount locations 114 a, 114 b, 114 c, 114 d, 114 e, 114 f, 114 g, 114 h.The embodiment shown includes the motion control chips 250 attached toeach of the attachable spindle modules 200. However, in otherembodiments, these motion control chips may be found on the spindle bank100. Whatever the embodiment, the dispensing head or pick-and-place headdefined by the combination of the spindle bank 100 and the attachedspindle modules 200, 500 may include a number of control chips 250 equalto the number of spindles. In other embodiments, each spindle module 200includes a single one of the control chips 250 dedicated to the twospindles located on the module.

Various methods are contemplated for assembling unfinished products, orassembling assembly machines, utilizing the assembly machines,dispensing heads, spindles, spindle mounting modules and spindle banksdescribed hereinabove.

For example, a method of assembly may include providing a pick-and-placemachine, such as the assembly machine 10, having a pick-and-place head,such as the combination of the spindle banks 100 and one or more of thespindle modules 200. The method may include providing a spindle, such asthe spindle 300, for the pick-and-place machine. The method may includeattaching the spindle to the pick-and-place head of the pick-and-placemachine. The method may include engaging, by a theta gear of thespindle, with a motor, such as the first theta motor 224, of thepick-and-place head. The method may include contacting, by the spindle,an electronic component, or a portion thereof. The method may includemanipulating, by the spindle, the electrical component. The method mayinclude removing the spindle from the pick-and-place head of thepick-and-place machine to a spindle bank of the pick-and-place machine.The method may include receiving, by at least one opening in the shaftof the spindle, air flow into a hollow interior of the spindle from anair delivery system of the pick-and-place head and utilizing the airflowduring the manipulating. The method may include picking up, with thenozzle, the electrical component using the airflow, and placing, withthe nozzle, the electronic component using the airflow. The method mayinclude rotating, with the motor of the pick-and-place head, the thetagear of the spindle and rotating, by the rotating of the theta gear, theshaft and the nozzle tip of the spindle. The method may includebreaking, by a circumferential ridge of the spindle, a beam of anoptical sensor, such as the optical sensor 550, disposed on thepick-and-place head. The method may include sensing, by the opticalsensor, movement by the nozzle relative to at least a portion of thepick-and-place head. The method may include rotating, by the motor, thetheta gear by a magnetic force. The method may include receiving, by amagnet of a receiving location of the pick and place head, the shaftsuch that the magnetic material interacts with the magnet of thereceiving location.

Another method of assembly may include providing a pick-and-placemachine, such as the assembly machine 10 having a first movement axis,such as the third movement axis 36 or the fourth movement axis 38. Themethod may include providing a spindle bank, such as the spindle bank100, for a pick-and-place machine. The method may include mounting, oneach of a plurality of mount locations of the spindle bank, a mountablespindle module, such as the spindle module 200, 500, including at leastone pick-and-place spindle and nozzle, such as the spindle and nozzlecombination 300. The method may include assembling, by the receivedmountable spindle modules, at least one unfinished product. The methodmay include distributing air, by an air distribution system of theassembly machine, to the spindle bank, and distributing the air, by asecond air distribution system of the spindle bank, to each of themountable spindle modules after the mounting. The method may includedistributing electrical power, by an electrical power distributionsystem of the assembly machine, to the spindle bank, and distributingthe electrical power, by a second electrical power distribution systemof the spindle bank, such as the electrical connectors 130, 132, to eachof the mountable spindle modules after the mounting. The method mayinclude receiving, by at least one threaded attachment location of thespindle bank such as the threaded attachment locations 134, 136, atleast one threaded attachment component of the at least one of themountable spindle modules, such as the screws 246 a, 246 b. The methodmay include using, by an installer, only a hand tool and attaching theat least one of the mountable spindle modules to a selected one of theplurality of mount locations. The method may include attaching a bearingsystem of the spindle bank, such as the bearing system 112, to the firstmovement axis. The method may include moving the spindle bank along thefirst movement axis by the pick-and-place machine. The method mayinclude attaching the first movement axis to a second movement axis ofthe pick-and-place machine, such as the first movement axis 32 and/orthe second movement axis 34, and moving the spindle bank along thesecond movement axis by the pick-and-place machine. The method mayinclude mounting a first mountable spindle module to a first mountlocation of the spindle bank and mounting the second mountable spindlemodule to a second mount location, wherein the second mountable spindlemodule is different than the first and wherein the second mount locationincludes different physical properties than the first mount location.

Another of assembly may include providing a pick-and-place machine, suchas the assembly machine 10, having a first movement axis, such as thethird movement axis 36 or the fourth movement axis 38. The method mayinclude providing a spindle bank, such as the spindle bank 100 attachedto the pick and place machine such that the spindle bank is movablealong the first movement axis. The method may include providing a firstpick-and-place spindle module, such as the spindle module 200. Themethod may include attaching, using a mechanical attachment mechanismsuch as the screws 246 a, 246 b, the first pick-and-place spindle moduleto the spindle bank such that an air distribution port, such as one ofthe air distribution ports 232, 234, is connected to receive air from anelement, such as air outlets 126 a, 126 b, 126 c, 126 d, 126 e, 126 f,126 g of the spindle bank and the electrical distribution port, such asthe electrical distribution ports 240 a, 240 b, 242 a, 242 b isconnected to receive electricity from an element, such as the electricalconnectors 130, 132 of the spindle bank. The method may includereceiving, by a receiving location of the modular body structure, afirst spindle, such as the spindle 300. The method may include moving,by a first z-axis motor such as the z-axis motor 220, the received firstspindle in a z-axis. The method may include rotating, by a first thetamotor such as the first theta motor 224, the received first spindle. Themethod may include delivering, by the air distribution system, receivedair from the air distribution port to the received first spindle. Themethod may include delivering, by the electrical distribution system,received electricity from the electrical distribution port to thereceived first spindle. The method may include moving the spindle bankalong the first movement axis and at least partially assembling, by theattached first pick-and-place spindle module, at least one unfinishedproduct. The method may include attaching the first pick-and-placespindle module to the spindle bank with a hand tool. The method mayinclude receiving, by a second receiving location of the modular bodystructure, a second spindle such as the spindle 300. The method mayinclude moving, by a second z-axis motor such as the second z-axis motor222, the received second spindle in the z-axis. The method may includerotating, by a second theta motor such as the second theta motor 226,the received second spindle. The method may include delivering, by theair distribution system, received air from the air distribution port tothe received second spindle and delivering, by the electricaldistribution system, received electricity from the electricaldistribution port to the received second spindle. The method may includemoving, by the first z-axis motor, a first body, such as the first body282, along a first linear track, such as the first linear track 278. Themethod may include moving, by the second z-axis motor, the second body,such as the second body 284, along a second linear track, such as thesecond linear track 280. The method may include attaching the firstlinear track and the second linear track to the modular body structurewith a set screw, such as the set screw 297 extending between a firstnut and a second nut, such as the first and second nuts 298 a, 298 b.

The method may further include controlling, with a first motion controlchip of the spindle module, such as the motion control chip 250, thefirst z-axis motor and the first theta motor. The method may includecontrolling, with a second motion control chip, the second z-axis motorand the second theta motor.

The method of assembly may also include providing a secondpick-and-place spindle module, such as the spindle module 500 or 200.The method may include attaching, using the mechanical attachmentmechanism, the second pick-and-place spindle module to the spindle banksuch that the air distribution port of the second pick-and-place spindlemodule is connected to receive air from an element of the spindle bankand the electrical distribution port of the second pick-and-placespindle module is connected to receive electricity from an element ofthe spindle bank. The method may include receiving, by a receivinglocation of a modular body structure of the second pick-and-placespindle module, a spindle. The method may include moving, by the firstz-axis motor of the second pick-and-place spindle module, the receivedspindle of the second pick-and-place spindle module in a z-axis. Themethod may include rotating, by the first theta motor of the secondpick-and-place spindle module, the received spindle of the secondpick-and-place spindle module. The method may include delivering, by theair distribution system of the second pick-and-place spindle module,received air from the air distribution port of the second pick-and-placespindle module to the received spindle of the second pick-and-placespindle module. The method may include delivering, by the electricaldistribution system of the second pick-and-place spindle module,received electricity from the electrical distribution port of the secondpick-and-place spindle module to the received spindle of the secondpick-and-place spindle module. The method may include at least partiallyassembling, by the attached second pick-and-place spindle module, the atleast one unfinished product. The method may still further includecontrolling, with a first motion control chip, the first z-axis motor ofthe first pick-and-place spindle module and the first theta motor of thefirst pick-and-place spindle module, and controlling, with a secondmotion control chip, the first z-axis motor of the second pick-and-placespindle module and the first theta motor of the second pick-and-placespindle module.

Methods of assembly may further include providing a pick-and-place headthat includes a body structure such as the modular body structure 210and/or the base 110 of the spindle bank 100, or any other body for apick-and-place or dispensing head. The method may include providing aplurality of z-axis motors attached to the body structure, eachconfigured to move a spindle in a z-axis and a plurality of theta motorsattached to the body structure each configured to rotate a spindle. Themethod may include providing a plurality of motion control chips eachattached to the body structure. The method may include controlling, witheach of the plurality of motion control chips, a single one of theplurality of z-axis motors and a single one of the plurality of thetamotors, and at least partially assembling, with the pick and place head,an unfinished product. The method may include controlling, with each ofthe plurality of motion control chips, speed of a single one of theplurality of z-axis motors and a single one of the plurality of thetamotors. The method may include controlling, with each of the pluralityof motion control chips, acceleration of a single one of the pluralityof z-axis motors and a single one of the plurality of theta motors. Themethod may include controlling, with each of the plurality of motioncontrol chips, position of a single one of the plurality of z-axismotors and a single one of the plurality of theta motors. The method maystill further include creating, with each of the plurality of motioncontrol chips, a separate independent motion control profile for each ofthe plurality of spindles.

Elements of the embodiments have been introduced with either thearticles “a” or “an.” The articles are intended to mean that there areone or more of the elements. The terms “including” and “having” andtheir derivatives are intended to be inclusive such that there may beadditional elements other than the elements listed. The conjunction “or”when used with a list of at least two terms is intended to mean any termor combination of terms. The terms “first” and “second” are used todistinguish elements and are not used to denote a particular order.

While the invention has been described in detail in connection with onlya limited number of embodiments, it should be readily understood thatthe invention is not limited to such disclosed embodiments. Rather, theinvention can be modified to incorporate any number of variations,alterations, substitutions or equivalent arrangements not heretoforedescribed, but which are commensurate with the spirit and scope of theinvention. Additionally, while various embodiments of the invention havebeen described, it is to be understood that aspects of the invention mayinclude only some of the described embodiments. Accordingly, theinvention is not to be seen as limited by the foregoing description, butis only limited by the scope of the appended claims.

What is claimed:
 1. A method of assembly comprising: providing apick-and-place head that includes: a body structure having first andsecond receiving locations to receive first and second spindles; a firstz-axis motor attached to the body structure, and configured to move thefirst spindle in a z-axis; a second z-axis motor attached to the bodystructure and configured to move the second spindle in the z-axis; afirst theta motor attached to the body structure and configured torotate the first spindle in a theta rotational axis; a second thetamotor attached to the body structure and configured to rotate the secondspindle in the theta rotational axis; a first motion control chipattached to the body structure dedicated to controlling the first z-axismotor and the first theta motor; and a second motion control chipattached to the body structure dedicated to controlling the secondz-axis motor and the second theta motor; creating, with each of thefirst and second motion control chips, a separate independent motioncontrol profile for each of the first and second spindles; controlling,with the first motion control chip, the first z-axis motor and the firsttheta motor based on the separate independent motion control profile forthe first spindle; controlling, with the second motion control chip, thesecond z-axis motor and the second theta motor based on the separateindependent motion control profile for the second spindle; and at leastpartially assembling, by the pick-and-place head, a product.
 2. Themethod of assembly of claim 1, further comprising: controlling, with thefirst motion control chip, speed of the first z-axis motor and the firsttheta motor; and controlling, with the second motion control chip, speedof the second z-axis motor and the second theta motor.
 3. The method ofassembly of claim 1, further comprising: controlling, with the firstmotion control chip, acceleration of the first z-axis motor and thefirst theta motor; and controlling, with the second motion control chip,acceleration of the second z-axis motor and the second theta motor. 4.The method of assembly of claim 1, further comprising: controlling, withthe first motion control chip, position of an output of the first z-axismotor and the first theta motor; and controlling, with the second motioncontrol chip, position of an output of the second z-axis motor and thesecond theta motor.